I've ordered my parts to do this install: New evaporator, new dryer, new orifice line, new o rings, and a new heater core. The factory service manual says I need a special tool to separate the AC lines. A refrigerant line spring lock coupler disconnect tool. Is this necessary? I was also wondering about any gaskets I might need to replace in the dash or behind the HVAC box. I know this is a time consuming project and I am up for the challenge. I would just like to have all the parts and tools before I begin. Any advice would be greatly appreciated

 

Yes, you do need a special disconnect tool. They are very cheap though and can be found at most auto parts stores. Normally they come packaged as "A/C and Fuel Quick Disconnect Tools".

 

Might as well replace the condensor and compressor too if you are doing all this.

 

Seems like someone post a while back about replacing the firewall foam gasket assembly or something to that affect. I guess it seals between the HVAC box and firewall. Probably a dealer item but worthwhile to check into. Good luck.

New rubber hose/manifold assembly?

 

I was wanting to pry open the evap covers to see and possibly clean the intake side of evaporator.....whoa! found out the entire dash has to come out!

Our 94 XJ Sport was inherited when my Father-in-law passed.

The way they built the Jeep around the evaporator/heater core box is the worst I've ever seen and I have worked on many makes and models.

Luckily just my compressor went, and I was able flush out the lines and evap and condenser. Installed new dryer and it held 30 lbs of vacuum overnight.

So, for now the dash is still untouched. NOT looking forward to that job!

And after replacing the rear springs due to one being broken (found during brake replacement) the rear shock bolts breaking off and having to drill them out upside down. (installed air shocks). I don't think I'll ever buy a new Jeep.
Everytime I go to repair something there's an issue which involves more time and cash to fix it right. Its been a nightmare. We don't even go off roading! I cannot imagine the problems those guys run into.